Method of weaving jacquard pile fabric



Aug. 13, 1963 T. T. JANNEY METHOD OF WEAVING JACQUARD FILE FABRIC 5 Sheets-Sheet 1 Filed June 5, 1960 mvzu'roa: THOMAS T JANNEY ATTY 1963 T. T. JANNEY 3,100,510

METHOD OF WEAVING JACQUARD FILE FABRIC Filed June 3, 1960 5 Sheets-Sheet 2 F155. 7 FEE. j

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MOVABLE KNIVES sT/ l n ga /k *7- MIDDLE e a W L.

, BOTTOM GRATE INDEX TOP SHOT BOTTOM SHOT INVENTOR. THOMAS T. JANNEY ATTY.

Aug. 13, 1963 T. T. JANNEY METHOD OF WEAVING JACQUARD PILE FABRIC 5 Sheets-Sheet 3 FHEIE].

Filed June 3, 1960 FIGS.

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INVENTOR: THOMAS T. JANNEY ATT Y.

Aug. 13, 1963 T. T. JANNEY METHOD OF WEAVING JACQUARD PILE FABRIC 5 Sheets-Sheet 4 Filed June 5, 1960 INVENTORI THOMAS T. JANNEY 0 ATTY.

3, 1963 T. T. JANNEY 3,100,510

METHOD OF WEAVING JACQUARD FILE FABRIC Filed June 3, 1960 5 Sheets-Sheet 5 INVENTOR.

THOMAS T JANNEY ATTY.

United States Patent Ofiice 3,100,510 METHOD OF WEAVING .IACQUARD PILE FABRIC Thomas T. .lanney, Buena Vista, Va., assignor to James Lees and Sons Company, Bridgeport, Pa., a corporation of Delaware Filed June 3, 1960, Ser. No. 33,759 14 Claims. (Cl. 139-43) This invention relates to an improved pile fabric and method for weaving the same. More particularly it pertains to the method of weaving a Wilton-type floor covering in which it is possible to selectively weave high floats, low floats, and carry the pile yarns through to the back in a wire-on-shot weave.

In the Wilton carpet and upholstery fabric arts a jacquard mechanism is used to control selected pile yar-n ends to produce what are commonly known as floats. Parlin Patent No. 2,685,894 discloses one type of jacquard capable of weaving such floats. Ianney Patent No. 2,807,283 pertains to a type of jacquard which also weaves floats but in a somewhat different manner. The Parlin jacquard, for example, indexes in a midposition and can produce high floats, intermediate floats, and low floats and it can produce a through-to-the-back Wilton fabric as shown in FIGS. -12 of the patent. The Janney jacquard of Patent No. 2,807,283 represents an improvement over Parlin since it is more efficient and less expensive. However,.it does not produce a throughto-the-back fabric because all pile ends must be selected to an elevated position when the bottom shot is inserted.

The present invention pertains to a modification of the jacquard in which there are two selections or indexings of the jacquard hooks per weaving cycle. In other words on the first index of the pattern mechanism the pile warps ars positioned in any one of three positions and the first filling shot is made. On the second index the pile warps are selectivelymoved to other positions and the second filling shot is made, thus performing a weaving cycle.

In this way by suitable cutting of the cards it is possible to produce a two-shot, wire-onshot Wilton weave in which each pile yarn on the first selection of the cycle is selectively controlled'to weave in any one of four positions: first, fully elevated to work over a pile wire or wires; second, in the mid position to work under a pile wire or wires and over the top shot; third, to run dead between top and bottom shots; fourth, in the bottom position for both indexes to work under both the top and bottom shots which provides a through-to-theback or floaton-the-back weave. On the second indexing or selection of the jacquard cards the grate is raised to a mid position, the griff is lowered, and each pile yarn end can be selected to Work over the bottom shot or under the bottom shot. Since eachsecond selection of the cycle controls the Working of all the pile yarn with respect to the bottom shot, it will be apparent that on the second half of the cycle any pile yarn may be selected to run dead over the bottom shot or to weave through to the back beneath the bottom shot.

3 719'05 l Patented Aug. 13, 1 963 A primary object of the invention is to provide methods for weaving a Wilton type fabric in which it is possible to select any pile yarn to any one of three positions for alternate weft insertions.

A further object of the invention is to provide a method of weaving a Wilton type fabric in which it is possible to combine in the same fabric a maximum number of pile height effects.

A further object of the invention is to provide a method of weaving a Wilton type pile fabric in which it is possible to control every pile yarn to run on the back of the fabric, between upper and lower weft shots, between upper weft shots and pile wires, and over pile wires.

A further object of the invention is .to provide a method of weaving a Wilton type pile fabric in which the pile yarns can be controlled to weave in any one of four positions for every shot by means of a three position double selective jacquard.

A further object of the invention is to provide maximum pile yarn control to four positions in a two shot,

three frame, Wilton type fabric.

Further objects will be apparent from the specification and drawings in which:

FIGURES 1-4 are Weave diagrams showing various possible combinations for controlling each and every pile yarn in an improved Wilton type fabric in accordance with the present invention;

FIGURE 5 is a shed diagram illustrating the insertion of the wire and top shot;

FIGURE 6 is a shed diagram similar to FIGURE 5 showing the second index in a cycle after which the blOttom shot is inserted;

. FIGURE 7 is a schematic weave diagram showing the selections for one cycle;

FIGURE 8 is an enlarged diagrammatic view of a part of the jacquard mechanism showing the card cylinder after rotating to presenta new card to the jacquard and just prior to indexing;

FIGURE 9 is a view similar to FIGURE 8 with the card cylinder advanced to complete the indexing or selection of the hooks;

FIGURE 10 shows the jacquard hooks moved to the selected-positions in accordance with the control of the jacquard cards. In this showing the pile warp heddle is raised to a top position over a pile wire;

FIGURE 11 shows either the same jacquard hooks on a subsequent indexing or different hooks on the same indexing in which the jacquard card has rejected both hooks, thus permitting the pile warp controlled by 'the associated lingo heddle to drop to a bottom position;

FIGURE 12 again shows the same two jacquardhooks in a subsequent indexing or different hooks on the same. indexing in which the jacquard has rejected one hook and selected another to retain the pile warp in a middle position; and

FIGURES 1 3 and 14 are views corresponding generally to FIGURES 11 and 12 but on the second index in the cycle in which the griff remains stationary. The selection in the second index, therefore,v is only between a bottom position, shown in FIGURE 13, and a middle position (over the bottom shot), as shown in FIGURE 14. Again the jacquard hooks of FIGURES 13 and 14 may be either the same hooks on a subsequent index or different hooks on the same index. 7

Referring now to the drawings, FIGURES l-4 are warpwise weave diagrams showing the various weave characteristics obtainable in the same piece of fabric by means of the present invention. In FIGURE 1 there is shown a high float HF in which the pile yarn 20 is carried over two consecutive pile wires 21 and 22. It will be understood that the high float HF may be continued so that pile yarn 20 is carried over any number of the pile wires that may be desired. A low float LP is also shown in FIG- URE l in which pile yarn 20 is carried under pile wires 23 and 24 and over the top filling shots 25 and 26. Likewise, the low float LF can continue in the same manner indefinitely as may be called for by the jacquard cards. A third position for the pile warp ZIP is shown at R1) in which the pile yarn runs dead between the upper shots 27, 27

and the bottom shots 28,28. The fourth position for the" pile yarn 20 or any given pile yarn in the fabric is shown at BF which indicates the yarn floating-on the back of the fabric for as long as may be desired. In this case the yarn 20 is carried below the bottom shots 29, 3t), and 31.

In FIGURE 2, however, I have shown a manner in which the pile yarn 20 or any pile yarn in the fabric may change not only the ultimate result and configuration of the fabric but also the manner in which the designer is permitted to vary the manner of the weaving of any pile yarn after every insertion of any filling shot. FIGURE 2 also indicates the weaving of a [flat weave FW in which the pile warp yarn 20a is carried under every bottom shot 32 and over intermediate top shots 33,33. Instead of working over just the top shots 33, the yarn may also be carried over one of the pile wires 34 and then subsequently over every pile wire while being tied in under consecutive bottom shots. These wires may be round, as shown at 34,34, or serrated, as shown at 36, or cutting, as shown at 35,37. The cutting wires may be high 35 or low 37. By a judicious co-relation between the type and characteristics of the pile wires and the jacquard selection of "the specific yarns, it is possible to achieve awide variety or range of pile fabric textures. I

In FIGURE 3, I have illustrated an intermediate float IF in which pile yarn 20 works from a running dead position thence under a wire 35 and :over top shot 36 to be carried over a pile wire 37. Proper cutting of the jacquard cards thereupon controls pile 20 to weave through to the back under bottom shot 38. The intermediate floats can be reversed so that the yarns run from over a pile wire 40 thence under pile wire 41 over top shot 42 and thence directly under the succeeding bottom shot 43. Alternatively, the intermediate floats can be terminated by tying them in under certain of the top shots 44 and 45 'or they can continue to form a low float under wires 46 and 47 for as long as may be desired.

In FIGURE 4 the pile yarn20 is carried from a running dead position between the top'shots 46 and bottom shots 47 to a point where it subsequently works under bottom shot48, thence directly up and over the next succeeding top shot 49 .to provide a low float. A normal wire-on-shot Wilton or velvet weave is shown at the right in FIGURE 4 in which the pile yarn 20 weaves over a pile wire 50 under the subsequent top shot51 and over the next succeeding wire 52.

IA three frame Wilton weave will customarily use three separate sets of pile yarn ends in each dent, and it will be understood that the showings of FIGURES 1 and 3 may be applied to anyone of the three frames so that the yarn control weftwise of the fabric in which each frame has an entirely separate characteristic or manner of working 1 importance in providing better anchorage or bind for the pile yarns, better dye penetration in the event piece dyeing is employed, and also to provide some design or identification on the back of the fabric if desired.

Referring now to FIGURES 5 and 6, a shed diagram is shown in which the upper shed position 60 may be con sidered representative of one frame, the middle shed position '61 representative of the second frame, and the bottom shed position 62 representative of the third frame. The

pile yarns of frame 60 are controlled by a series of lingo heddles 63 and the yarns of frame 61 by lingo heddles 64 and likewise the yarns of frames 62 by lingo heddles 65.

After insertion of the wire W, which may be any one of the wires shown in FIGURES l-4, the top shot 66, which likewise may be any one of the top shots of FIGURES 1-4, the reed 67 beats up the wire and shot 66 into the fell F of the fabric. As will be explained more fully hereinafter, any one of the pile yarns may be selected to any one of the three positions shown in FIGURE 5. At any particular indexing the three frames may all be in the same position, in three separate positions, or two of them in any one position and the third in any other position. It will thus be understood that an extremely wide variety of permutations and combinations of pile yarn control can be accomplished.

FIGURE 6 illustrates the second indexing in which the yarns are selected to either the middle or the bottom position. In this case any pile yarn may be selected to either of the two positions but not to a top position. LAS illustrated, frame60 has been dropped to a bottom position by means of its heddle 63. Both frames 61 and 62 have been retained at a middle position by means of their associated heddles 64 and 65. After this indexing has taken place the bottom shot 7 0, which may be any of the bottom shots of FIGURES 1-4, is inserted into the shed and the reed 67 beats up the bottom shot to the fell as in conventional weaving.

The above described selections with regard to the frames are shown schematically in FIGURE 7, which have been labeled to correspond to the jacquard positions to be described more fully herein-after. It is to be noted that the first index precedes a selection to threepositions and the second index precedes a selection to a middle or bottom position.

To completely follow the operation of the jacquard and the manner in which the jacquard cards are cut or punched, reference is made to FIGURES 8-14. The card cylinder of the jacquard is rotatable on its axis 76 and also oscillates from a retracted position, shown in FIG- URE 8, to an indexing position, shown in FIGURES .9 and 10. When in the retracted position, the cylinder 75 turns to present a new card 77 to the jacquard needles 78 and 79 for each indexing. The needles 7'8 and 79 are spring loaded in the conventional manner and are displaceable in needleboard 80 to control respectively books 81 and 82.

When a new card such as 90 is presented to the needles the cylinder 75 slides to an indexing position shown in FIG. ,9 to actuate the needles and the hooks in accordance with the manner in which the cards 77 have been cut. In FIGURE 9 the initial indexing is illustrated in which the grate 85 is in anelevated position and supports the needles 81 and 8-2 by means of tangs 86, 86 on each hook. The harness cords 87 are connected to the bottoms of the hooks and the other ends of cords 87 are'connected in pairs to a single lingo heddle 88 which is weighted by means of the usual lingo 89. It will be understood that there is a heddle 88 for each pile warp yarn in the fabric. The illustrations herein are confined to'the actuation of only one of many heddles in order that the action may be more clearly understood. In the index shown in. FIG- URE 9', the'card '90 is cut for the upper needle 78 and is blanked for the lower needle 79 so that as thecylinder. advances, hook 81 is not displaced but remains in alignment with one of the knives 91 of the grilf." The other hook 82, controlled by needle 79, is displaced because of the blanked portion of card 90, and is moved out of alignment with the stationary knife 92. In the next portion of the cycle the grate 85 descends to the position shown in FIGURE 10. Simultaneously, the griif carrying knife 91 elevates so that the hook 81 is raised to a top position, thereby elevating the lingo heddle 88. Since book 82 is displaced, it does not engage the stationary knife 92. This action eliminates any control of the heddle by means of the hook 82. With the knife 91 in the elevated position, any top shot 66 is inserted together with the pile wire W. In this particular instance the pile yarn Y is carried over a single insertion of the wire W as well as the top shot 66.

FIGURE 11 shows the actuation of the same needles and hooks on a subsequent indexing, or it will be understood that it could be difierent hooks in the jacquard on the same indexing as shown in FIGURES 8-10. In this case both needles 78 and 79 are displaced because the jacquard card 93 on cylinder 75 is blanked for these two needles. When the grate 85 descends, as shown in FIG- URE 1'1, neither hook is engaged on the knives 91 or 92, thus permitting the hooks to drop with the grate 85 and position the yarn Y in the bottom shed position. If the wire W and top shot 66 are inserted in the yarn Y in tllilis bottom position, the pile yarn weaves under the top s t.

FIGURE 12 illustrates the selection to a mid position during the same or a subsequent indexing. In this case jacquard card 9 is blanked for needle 78 and cut for needle 79. This action does not displace hook 82 but does displace hook 8 1 so that it is not engaged bythe movable knife 91. Hook 82, however, is arrested and held in the mid position by the stationary knife 92 so that when the grate '85 descends, the heddle 88 is retained in a mid position and the nvire W is inserted on top of the yarn Y but top shot '66 is inserted beneath the yarn Y. This provides weaving of the pile yarn under the wire and over the top shot, as may be seen in FIGURES 1, 3, or 4. The above three selections permit the pile yarn on every pick to weave over the wires, between the wire and the top shot, or under the top shot. The further action of the pile yarn is controlled during the second index when the bottom shot is inserted.

With reference to FIGS. 13 and 14, it will be noted that these figures correspond generally to FIGURES 11 and 12 except that the grifi is not elevated and, therefore, the movable knife 91 remains in its initial position. On

the second index, if the card 95 is blanked for both needles,

they will each be displaced and the hooks lowered to a bottom shed position for the insertion of the bottom shot 70 which will be over the yarn Y. In this condition the pile yarn Y will weave through to the back whereupon, depending upon the next index, it may be floated on the back or be carried up to work in any possible manner that may be desired. If the yarn Y is to be carried over the bottom shot 70, the card cutter then blanks the card 96 for needle 78 and cuts the card for needle 79. This in turn holds the heddle 88 in a mid position when .grate 85 descends by means of the engagement between hook 82 and stationary knife 92. The yarn Y then is carried over the bottom shot 7!) so that the yarn does not weave through to the back. Here again, the showing of FIG. 14 may illustrate the same needles and hooks on a subsequent indexing or different needles and hooks in the jacquard in the same indexing as that of FIG. 13.

The following tabulation indicates some but not all of the various limitations and combinations possible with the present weaving invention. From them it will be noticed that there is a wide range of selections and control of each pile yarn during the entire weaving process. The reference letters in the table refer to brackets in FIG- URES 1-4 for the purpose of identifying the particular type of weave achieved with the corresponding first, second, and third indexes.

6 Jacquard Control of Any Pile Yarn in Two-Shot, T hree-Frame Wilton First Second Third Figs. indexindexindex- 14, For Wire For bottom For wire ref- Weave eiiect and top shot and top erence shot shot Top Middle Top A High float over any desired number of wires. Middle Middle Midd1e B Low float under any desired number of wires and over top shots.

Bottom Bottom.. Bottom 0 Float on the back of fabric indefinitely until tied in.

Bottom-.. Middle Bottom D Running dead in ground fabric between top and bottom shots.

Middle-.- Bottom Middle E Through to the back and under next wire.

Top Bottonn- Top F Weave over consecutive wires and through to the back between said wires.

Middle.-- Middle..." Bottom G Under wire and then running dead.

Middle--- Middle. Top H Intermediate float over four consecutive shots and one wire.

Bottom. Middie Top I High pile projection if out, high loop if uncut, as compared to F.

Bottom Bottom Middlc 3' Running dead through to the back and then r on top of ground fabric.

Top Middle Middlc. K Over two consecutive top shots and the intermediate bottom shot and one wire.

Top.. Middle Bottom L Over alternate wires and top shots.

Nora-The wire in both E and K can be over either of the two top shots; i.c., the first and third indices may be transposed.

Having thus described my invention, I claim: 1. The method of weaving on -a two index per weaving cycle jacquard loom, a Wilton fabric having ground warps, filling shots, and a series of pile yarns which comprises the steps of selecting each pile yarn to one of three shed positions on the first jacquard index, inserting a filling shot, selecting each of said pile yarns to one of two positions on the second jacquard index, and inserting a filling shot.

2. In the weaving of Wilton pile fabrics on a two index per weaving cycle jacquard loom the method of controlling the shedding of pile yarns which comprises the steps :of selecting a first group \of pile yarns to a top shed position, selecting a second group of pile yarns to a middle shed position, selecting the remaining yarns to a bottom shed position, all on the first cycle index, inserting va wefit shot, then on the second cycle index selecting certain of the pile yarns to a mid position and the remainder of said pile yarns to a bottom position, and insetting a filling shot.

3. In the weaving of la Wilton type fabric on a two index per weaving cycle jacquard loom the steps comprising selecting certain pile yarns to a top shed position on the first index of the cycle, inserting a filling shot, selecting the same pile yarns to a middle position on the second index of the cycle, inserting a filling shot, selecting the same pile yarns to :a top shed position on the first index of the next cycle, and inserting a filling shot.

4. In the weaving of 1a Wilton type fabric on a two index per weaving cycle jacquard loom the steps comprising seleoting centain pile yarns to a middle shed position on the first index of the cycle, inserting a filling shot, selecting the same pile yarns to a middle position on the second index of the cycle, inserting a filling shot,

selecting the same pile yarns to a middle shed position on the first index of the next cycle, and inserting a filling shot.

5. In the weaving of a Wilton type fabric on a two index per weaving cycle jacquard loom the steps comprising selecting certain pile yarns to a bottom shed position on the first index of the cycle, inserting a filling shot, selecting the same pile yarns to a bottom position on the'second index of the cycle, inserting a filling shot, selecting the same pile yarns to a bottom shed position on the first index of the next cycle, and inserting a filling shot.

6. In the weaving of a Wilton type fabric on a two index per weaving cycle jacquard loom the steps comprising selecting certain pile yarns to a bottom shed po- 8 ing the same pile yarns to a stop shed position on the first index of the next cycle, (and inserting a filling shot.

11. In the weaving of a Wilton type fabric on a two index per weaving cycle jacquard loom the steps comprising selecting certain pile yarns [to 'a bottom shed position on the first index of the cycle, inserting a filling shot,

sition on the first index of the cycle, inserting a filling shot, selecting the same pile yarns to a middle position on the second index of the cycle, inserting a filling shot, selecting the same pile yarns (to a bottom shed position on the first index of the next cycle, and inserting a filling shot.

7. In the weaving of a Wilton type afiabr-ic on a two index per weaving cycle jacquard loom the steps comprising selecting certain pile yarns to a middle shed position on the first index of the cycle, inserting a filling shot, selecting the same pile yarns to a bottom position on the second index of the cycle, inserting a filling shot, selecting the same pile yarns to a middle shed position on the first index of the next cycle, and inserting :a filling shot.

8. In the weaving of la Wilton type fabric on a two index per weaving cycle jacquard loom the steps comprising selecting certain pile yarns to :a top shed position on the first index of the cycle, inserting a filling shot, selecting the same pile yarns to a bottom position on the second index of the cycle, insetrting a filling shot, selecting the same pile yarns to a top shed position on the first index of the next cycle, and inserting a filling shot.

9. In the weaving of :a Wilton type tabric on a two index per weaving cycle jacquard loom the steps comprising selecting certain pile yarns to a middle shed position on the first index of the cycle, inserting a filling shot, selecting the same pile yarns to a middle position on {the second index of the cycle, inserting a filling shot, selecting the same pile yarns to a bottom shed position on the first index of the next cycle, and inserting a filling shot.

10. In the weaving of a Wilton type fiabric on a two 7 index per weaving cycle jacquard loom the ste s comprising selecting certain pile yarns to a middle shed position on the first index of the cycle, inserting a filling shot, selecting the seine pile yarns to a middle position on the second index of the cycle, inserting a filling shot, selectselecting the same pile yarns to a middle position on the second index of the cycle, inserting a filling shot, selecting the same pile yarns to a top shed position on the first index of the next cycle, and inserting a filling vshot.

12. In the weaving of la Wilton type iabricon a two index per weaving cycle jacquard loom the steps comprising selecting certain pile yarns [to a bottom shed position on the first index of [the cycle, inserting a filling shot, selecting the same pile yarns to a bottom position on the second index of the cycle, inserting a filling shot, selecting the same pile yarns to a middle shed position on the first index of the next cycle, and inserting a filling shot.

:13. In the weaving of a Wilton type fabric on a two index per iweaving cycle jacquard loom the steps comprising selecting certain pile yarns to a top shed position on [the first index of the cycle, inserting a filling shot, selecting rthe same pile yarns to a middle position on the second index of the cycle, inserting a filling shot, selecting the same pile yarns to a middle shed position on the first index of the next cycle, and inserting a filling shot.

:14. In the weaving of a Wilton type fabric on a two index per weaving cycle jacquard loom the steps comprising selecting certain pile yarns to a top shed position on the first index of the cycle, inserting a filling shot, selecting the same pile yarns to a middle position on the second index of the cycle, inserting :a filling shot, selectthe same pile yarns to a bottom shed position on the first index of the next cycle, and inserting a filling shot. 

1. THE METHOD OF WEAVING ON A TWO INDEX PER WEAVING CYCLE JACQUARD LOOM, A WILTON FABRIC HAVING GROUND WARPS, FILLING SHOTS, AND A SERIES OF PILE YARNS WHICH COMPRISES THE STEPS OF SELECTING EACH PILE YARN TO ONE OF THREE SHED POSITIONS ON THE FIRST JACQUARD INDEX, INSERTING A FILLING SHOT, SELECTING EACH OF SAID PILE YARNS TO ONE OF TWO POSITIONS ON THE SECOND JACQUARD INDEX, AND INSERTING A FILLING SHOT. 